Flooring system

ABSTRACT

A joint for connecting two adjacent flooring panels together in a substantially vertical manner includes a rotatable locking member made of plastic, metal or another resilient material. The rotatable locking member is located within a groove or opening of one flooring panel and the second flooring panel has a tongue shaped to mate with the rotatable locking member. Upon installation, the rotatable member rotates and locks around the back of the tongue via a groove above the tongue. The rotatable locking member includes a resilient arm which is bent away from its initial rest position upon installation, so that when the rotatable locking member locks onto the tongue, the resilient arm is bent providing a biasing force which holds the panel securely in position.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to flooring systems. Moreparticularly, the present invention relates to mechanical locking jointsfor connecting flooring panels.

2. Discussion of the Related Art

Flooring systems are available in a variety of forms, such as fine wood,tile (e.g. granite, brick, slate, etc.), and concrete. Laminateflooring, such as laminates and high-pressure laminate boards (HPL), mayalso be a popular substitute for traditional flooring materials as theytend to be generally less expensive to produce. Regardless of which typeof flooring is desired, it is generally preferable to the user thatinstallation be simple, such that it is not necessary to hire aprofessional to install the system.

Methods of installation for flooring systems vary greatly. Fine woodflooring may requiring complicated nailing or gluing techniques in orderto lay and connect adjacent flooring panels. Tile flooring generallyrequires a grouting process which may be very tedious and complicated.In both cases, the hiring of a contractor or other professional may benecessary in order to install the flooring system properly.

Some of the related art flooring systems do not require gluing ornailing the flooring system to the base floor during installation. Thesetypes of flooring systems are popularly known as “floating floors” asthey do not generally rigidly connect to a base floor. Many floatingfloors may employ some type of interlocking joint system.

One type of interlocking joint is known as a tongue-and-groove-typeconnection, where each board has a tongue extending along one edge and amating groove extending along an opposite edge. Accordingly, wheninstalling the flooring panels the tongue of one panel is fitted intothe grove of an adjacent panel. Some types of tongue and grooveconnections for floor panels utilize a snap-together joint. With thistype of connection generally the tongue or groove will have anadditional protrusion or indentation that will serve to “snap” adjacentpanels together when a force is exerted to push the adjacent panelstogether.

Related art flooring system joint connections have a disadvantage inthat the floor planks when fitted together may not lie completely flush,but instead a gap or space remains between adjacent floor panels. Thismay be a particular disadvantage as dust, dirt, or other particles mayaccumulate in the gaps, creating an unattractive appearance andunsanitary conditions. Further, there stands a better chance that normalusage would serve to splinter or chip the flooring surface due tocatching the surface material as allowed by the above mentioned gap.

As noted above laminate flooring offers several advantages, such aslower production cost. Further, most laminate flooring is of the“floating floor” type utilizing an interlocking joint system, which maybe considered uncomplicated and easier to install. It is noted that mostlaminate flooring systems employ some type of decorative motif on asurface of the panels to mimic the look and feel of traditional flooringmaterials. In order to effectively create such a look, it may be veryimportant to align the decorative motifs or graphics across the jointsof adjacent panels. However, related joint systems in floor systemsgenerally have the disadvantage of creating a visual disruption in thesurface pattern of the laminate flooring. This significantly detractsfrom the visual and textural impression of system, resulting in anunattractive appearance of the flooring when it is installed.

Accordingly, what is needed is flooring system that is inexpensive,employing a joint connection that is easy to install, resulting in anaesthetically pleasing and durable appearance.

SUMMARY OF THE INVENTION

The present invention provides a mechanical locking joint connection foruse with flooring systems.

Accordingly, one advantage of the present invention is to provide amechanical joint system that connects adjacent floor panels. Anotheradvantage of the present invention is to prove a mechanical joint systemthat is easy to install. Yet another advantage of the present inventionis to provide a reliable connection that results in a pleasant aestheticappearance.

Additional advantages of the invention will be set forth in thedescription that follows, and in part will be apparent from thedescription, or may be learned by practice of the invention. Theadvantages of the invention will be realized and attained by thestructure pointed out in the written description and claims hereof aswell as the appended drawings.

To achieve these and other advantages, the present invention involves aninterlocking joint having a first side defining a first mating portionalong a first side and a second side defining a second mating portionalong a second side, said second side disposed opposite said first side;the first mating portion having a substantially arcuate groove formedtherein and extending along at least a portion of the first side; arotatable cam disposed in the groove extending in a longitudinaldirection along at least a portion of the first side; the rotatable camhaving a central portion, a first arm extending radially outward fromthe central portion along a first axis, a second arm extending radiallyoutward from the central portion along a second axis, and a resilientarm extending radially outward from the central portion along a thirdaxis and disposed a distance from the second arm defined by apredetermined angle; the first arm having a lever portion and a curvedportion, the curved portion extending substantially perpendicular to thelever portion defining a substantially hook-shaped end; a lower lipextending outward from the first mating portion beyond the groove; saidsecond mating portion having a tongue extending perpendicularly fromsaid second side and extending along at least a portion of the firstside and defining a substantially concave groove along an undersurfacereceiving said lower lip; said tongue having a substantially verticalface at least as long as the distance from the hook-shaped end of thefirst arm to the end of the second arm; said second mating portionfurther defining a locking groove formed therein above the tongue toreceive the hook-shaped end of the first arm of the rotatable cam; andthe second arm and the resilient arm bendable towards each other tocreate a biasing force, wherein the biasing force impels the third armtoward the tongue such that as the tongue advances in a direction towardthe first mating portion, the curved arm of the moves into a matingposition with the locking groove, thus providing a tight lockingconnection.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention andtogether with the description serve to explain the principles of theinvention.

FIG. 1 illustrates a side view of an exemplary rotatable memberaccording to the present invention.

FIG. 2 illustrates a side view of the rotatable member of FIG. 1, seatedin a groove within a floor panel.

FIG. 3 illustrates a side view of the mechanical joint connectionaccording to the present invention.

FIG. 4 illustrates a side view of the mechanical joint connection in alocked state.

FIG. 5 illustrates perspective view of the mechanical joint and flooringsystem according to the present invention.

FIG. 6 illustrates a side view of a second exemplary embodiment ofmechanical joint connection of the present invention.

FIG. 7 illustrates the mechanical joint connection according to FIG. 6.

FIG. 8 illustrates the mechanical joint connection according to FIG. 6.

FIG. 9 is a perspective view showing mechanical joint connectionsaccording to a further embodiment of the present invention and

FIG. 10 is a side view of the embodiment of FIG. 10.

FIG. 11 shows a mechanical joint connection according to a furtheraspect of the third embodiment of the present invention just prior tocompletion of installation and

FIG. 12 shows the joint connection of FIG. 11 in the closed installedcondition.

FIG. 13 is a side view of an exemplary rotatable insert member accordingto the fourth embodiment of the present invention having a grooveinstead of a rib, and

FIG. 14 is a side view of a similar insert member, but which has aconnection formed instead of a groove or rib.

FIG. 15 shows the mechanical joint connection according to fourthembodiment of the present invention with the insert of FIG. 13 justprior to completion of installation and

FIG. 16 shows the joint connection of FIG. 15 in the closed installedcondition, while

FIG. 17 shows the mechanical joint connection according to the fourthembodiment of the present invention with the insert of FIG. 14 justprior to completion of installation and FIG. 18 shows the jointconnection of FIG. 17 in the closed installed condition.

FIG. 19 shows a mechanical joint connection according to a fifthembodiment of the present invention just prior to completion ofinstallation and

FIG. 20 shows the joint connection of FIG. 19 in the closed installedcondition.

FIG. 21 illustrates a side view of an exemplary rotatable memberaccording to the present invention.

FIG. 22 is a side view of an exemplary rotatable member according to thesixth embodiment of the present invention having a groove and

FIG. 23 is a side view of a similar insert member, but which has aconnection instead of a groove.

FIG. 24 shows a mechanical joint connection according to a sixthembodiment of the present invention during initiation of installation,

FIG. 25, shows the sixth embodiment just prior to completion ofinstallation and

FIG. 26 shows the sixth embodiment in the closed installed condition.

FIG. 27 illustrates a side view of an exemplary rotatable memberaccording to the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

FIG. 1 illustrates an exemplary rotatable locking member 10 according tothe present invention, where the locking member 10 is in an unloadedstate. Rotatable locking member 10 includes a central region 16 definedas the portion surrounding core aperture 20, and a first arm 18extending radially from central region 16. Further, core aperture 20 hasa predetermined radius R1, which may depend on the size of the rotatablelocking member 10 and its particular application.

First arm 18 defines a substantially hook-shaped member. The hook-shapeof first arm 18 is created by the combination of lever portion 26 andcurved portion 28. Lever portion 26 may gradually increase in width asit extends from central region 16. Curved portion 28 extends integrallyfrom an end of lever portion 26, at a point farthest from central region16 and at a substantially perpendicular or acute angle, to end in asubstantially flat contact surface 30. First arm 18 further defines anarcuate hook groove 32 at an underside of thereof.

A second arm 22 also extends radially from central region 16 in adirection substantially opposite and parallel to that of the first arm20. Rotatable locking member further includes a resilient arm 24extending radially from the central region 16. As illustrated in FIG. 1,second arm 22 may increase in width as it extends from central region16, and resilient arm 24 may decrease in width. Other shapes of thesecond arm 22 and the resilient arm 24 are envisioned, so long as theyare enabled to provide a biasing force on the system, as discussedbelow.

As FIG. 1 illustrates, resilient arm 24 is radially offset from thefirst arm 18 by predetermined angle A1, and from the second arm 22 bypredetermined angle A2. In the illustrated unloaded state of FIG. 1, A1is generally an obtuse angle and A2 is generally an acute angle. Asforces begin to act upon locking member 10 A1 and A2 will changeaccordingly.

The rotatable locking member 10 may be made of plastic, metal, or anysuitable material that is resilient in nature such that it is capable ofwithstanding the forces imposed by the locking joint system while stillexerting a biasing force as described below.

FIG. 2 illustrates an exemplary embodiment where the locking member 10is seated in a first panel 12. The panel 12 may be made fromhigh-density fiber board (HDF), medium-density fiber board (MDF),particle board, composite, wood, or any other material used in flooringsystems. First panel 12 has a first side 34 defining a first matingportion, which includes a partially arcuate groove 36, having a front,slot-like opening 38, an upper arc 36A and a lower arc 36B. Disposedbetween upper arc 36A and 36B is a angled back wall 40 having an upperwall 40A and a lower wall 40B. The angle between upper wall 40A andlower wall 40B is substantially the same as angle A1. Lower arc 36B endsat front side 34 to create a lower lip 42 that extends laterally inlength beyond top edge 44.

FIG. 3 illustrates the interlocking function as first panel 12, havingrotatable locking member 10 seated therein, meets with second panel 14.Panel 14 may be constructed from substantially the same material aspanel 12. Second panel 14 includes a second side 46 defining a secondmating portion defined by tongue 48. Tongue 48 extends outwardly fromsecond side 46 and continues along at least a portion of the length ofsecond side 46. Further, the extension of tongue 48 from second side 46creates a substantially concave groove 50 along an undersurface thereofand a receiving groove 52 along an upper surface thereof.

During connection of panels 12 and 14, as illustrated in FIGS. 3 and 4,first panel 12 may be in place on the floor and second panel 14 isoriented substantially parallel to the floor. Second panel 14 and tongue48 are then lowered substantially vertically into the opening 38. Abottom edge 54 of tongue 48 contacts and presses against second arm 22of the rotatable locking member 10. As second panel 14 is pressed intofirst panel 12, bottom edge 54 forces the rotational movement of secondarm 22 toward resilient arm 24. Resilient arm remains stationary as itlies against lower wall 40B, which imposes a reactionary forcemaintaining the position of resilient arm 24. Accordingly, a bias forceis created about core aperture 20, thus pushing first arm 18 forwardsuch that surface 30 contacts top edge 56 of tongue 48.

As illustrated in FIG. 3, second panel 14 moves in a substantiallyvertical downward direction forcing tongue 48 to move second arm 22,thus decreasing angle A2. Further, as first arm 18 moves in a directiontoward second panel 14, in response to the generated bias force, angleA1 increases respectively. Contact surface 30 of first arm 18 willcontinue to bear against top edge 56 due to the bias force as tongue 48moves forward into opening 38. At a point where the lower edge 58 ofcontact surface 30 passes upper edge 56 of tongue 48, the first arm willmove immediately a distance forward. This movement may be described as a“click” into a locking position, such that curved portion 28 mates withcomplimentarily shaped receiving groove 52.

FIG. 4 illustrates an exemplary view of the mechanical joint system in aconnected or locked position. Tongue 48 is seated in a matingrelationship with a groove created by the front surface of rotatablelocking member 10, hook grove 32 and lip 42. Hook-shaped first arm 18 isbiased forward and seated in receiving groove 52, thus preventingvertical movement of first 12 and second 14 panels with respect to oneanother. Further, lower lip 42 is brought into mating alignment withconcave groove 50, thus preventing horizontal movement of first 12 andsecond 14 panels with respect to one another. First arm 18 and secondarm 22 maintain a vertical alignment in the locked position.

In FIG. 5 a perspective view of the exemplary joint locking system isillustrated. Locking member 10 is inserted into first panel 12 at a sidewall 60 thereof, and once inserted cannot be removed through slot-likegroove 38. Rotatable locking member 10 may be constructed in variouslengths in accordance with the scope of the invention. That is, lockingmember 10 may extend along the a portion of the length of first side 34or second side 44 (sides), or it may extend along the entire length ofthe sides. Further, where the locking member 10 is of a size that itdoes not extend along the entire length of the sides, but only a portionthereof, it is envisioned that more than one locking member 10 may beemployed.

A further exemplary embodiment is illustrated in FIGS. 6 through 8. Themechanical operation of the joint is similar to that described abovewith respect to FIGS. 2 though 4. In this exemplary embodiment, secondpanel 114 is installed into first panel 112, and is held in placethrough rotatable locking member 110. The second panel 114 has a tongue148 which mates with the rotatable locking member 110 seated in theopening 138.

As illustrated in FIG. 6, during installation, the second panel 114 isheld horizontally so that the of the second panel 114 is orientedsubstantially parallel to the floor. The second panel 114 is loweredinto the opening 138 of the first panel 112 substantially vertically,maintaining the second panel 114's substantially horizontal orientationwith respect to the floor.

As illustrated in FIGS. 6 and 7, as the second panel 114 enters theopening 138, the bottom edge 154 of tongue 148 pushes the second arm 122of the rotatable locking member 110, causing the second arm 122 torotate towards the resilient arm 124 and the first arm 118 to rotatetowards the tongue 148 until it presses against the top edge 156 of thetongue 148. The tope edge 156 of the tongue 148 prevents the first arm118 from rotating any further. Thus as the bottom edge 154 of tongue 148presses against second arm 122, the second arm 122 bends underincreasing force towards the resilient arm 124. Because the resilientarm 124 abuts the lower wall 40B of the opening 138 in the first panel112, the rotation of the second arm 122 under tension towards theresilient arm 124 imposes a reactionary force maintaining the positionof resilient arm 124 and pushing back against the second arm 122. Thiscreates a rotational bias force urging the resilient arm 124 and thesecond arm 122 apart.

When the second panel 114 completely enters the groove and lowers to itsfully installed condition, as illustrated in FIG. 8, the lower lip 142is fully inserted into the concave groove 150. Because the top edge 156of the tongue 148 passes below the hook-shaped or curved portion 128 ofthe first arm 118, the tension generated by the compressed angle betweenthe resilient arm 124 and the second arm 122 is released, causing thefirst arm 118 to rotate forward such that the curved portion 128 fitssecurely in to the groove 152.

Thus, when the present embodiment is in the installed condition, thefirst arm 118 and the second arm 122 are not under tension with respectto each other, however the resilient arm 124 is compressed radiallyagainst the second arm 122 creating a force pressing the tongue 148 backagainst the lower lip 142, and also pressing the top edge 156 backagainst the curved portion 128 of the first arm 118, therebyestablishing a locking engagement

In a further aspect of the present embodiment, as illustrated in FIG. 7,upper arc 136A and lower arc 136B of opening 138 are provided withslightly raised lip portions 162 and 164, respectively. The raised lipportion 162 and 164 engages a bump or raised tab 166 located at a topside of the first arm 118 opposite the curved portion 128 to prevent thefirst arm 118 from rotating out of the opening 138 causing the rotatablemember 110 to fall out of the opening 138. Likewise, the raised lipportion 164 on the lower arc 136B engages the front tip 166 of thesecond arm 122, preventing the second arm from rotating too far in thelower arc 136B, causing the rotatable member 110 to fall out of theopening.

In this exemplary aspect of this embodiment, the raised lip portion 162of the upper arc 136A, is placed a sort distance back from the opening138. The raised lip portion 164 of the lower arc 136B is placed near thebase of the lower lip portion 142.

In a further aspect of the invention, the raised lip portion 162 may beplaced in the upper arc 136A at a position such that when the secondpanel 114 is completely installed and the tongue 148 is seated entirelywithin the opening 138 and against the rotatable member 110, the raisedtab 166 on the first arm 118 hits the raised lip portion 162 before thefirst arm 118 returns to its initial position. This would cause there tobe some tension to remain between the first arm 118 and the second arm122 during installation to establish a tighter locking between thetongue 148, the rotatable member 110, and the first panel 112.

In yet another exemplary aspect of the present embodiment of theinvention, the angle separating the resilient arm 124 and the second arm122 can be made large enough so that prior to installation, the fronttip 166 of the second arm 122 is pressed slightly against the raised lipportion 164, maintaining the rotatable member 110 stationary in theopening 138, so that during manufacturing, shipping, and transport ofthe flooring panels, the rotatable member is not shaken loose of theopening 138.

A third embodiment of the present invention is illustrated in FIGS. 5,9, 10 and 27. In this embodiment, the rotatable locking member 200 (FIG.27) is provided with a head 202 at the end of first arm 218 having asubstantially convex shape. The rotatable locking member 200 includes asecond arm 222 and a resilient arm 224 having shapes similar to secondarm 18 and resilient arm 22 in FIGS. 1-4. As illustrated in FIGS. 9 and10, as the second panel 214 enters the opening 238, the bottom edge 254of tongue 248 pushes the second arm 222 of the rotatable locking member200, causing the second arm 222 to rotate towards the resilient arm 224and causing the first arm 218 to rotate towards the tongue 248 until itpresses against the top edge 256 of the tongue 248. The tope edge 256 ofthe tongue 248 prevents the first arm 218 from rotating any further.Thus as the bottom edge 254 of tongue 248 presses against second arm222, the second arm 222 bends under increasing force towards theresilient arm 224, which in turn is pressed against the back of opening238. Because the resilient arm 224 abuts the lower wall 240B of theopening 238 in the first panel 212, the rotation of the second arm 222under tension towards the resilient arm 224 maintains the position ofresilient arm 224 and pushing back against the second arm 222. Thiscreates a rotational bias force urging the resilient arm 224 and thesecond arm 222 apart.

When the second panel 214 completely enters the groove and lowers to itsfully installed condition, as illustrated in FIG. 10, the lower lip 242is fully inserted into the concave groove 250. Because the top edge 256of the tongue 248 passes below the convex shaped head 202 of the firstarm 218, the tension generated by the bending back of the first arm 218against the tope edge 256 of the tongue 248 is released, causing thefirst arm 218 to rotate forward such that the convex shaped head 202fits into the groove 252. In this embodiment, the convex-shaped head 202does not engage the groove 252, thus the lower lip 242 is provided witha substantially vertical surface 262 along some portion of its perimeterwhich is adjacent the rear surface 264 of the tongue 248. This preventsthe adjacent flooring panels 212 and 214 from sliding completely apart.

In this embodiment, the tongue may be shaped such that space may beprovided between the rotational locking member 200 and the front of thetongue 248. This space gives the rotational locking member 200 someflexibility to rotate or twist as the panels are installed or takenapart.

FIGS. 11 and 12 illustrate a second aspect of the third embodiment. Inthis aspect of the third embodiment, the tongue 270 has substantiallythe same shape as tongue 248 of FIG. 10, with the difference that therear surface 271 of the tongue 270 is a substantially smooth curve,lacking the vertical portion of rear surface 264 FIG. 10. Likewise thecorresponding opening in the first panel 272 does not have a verticalsurface on the lower lip 274. The absence of these two features allowsthe tongue 270 to slide more easily into the groove and to allow theflooring panels once installed to be removed or separated more easily.

In FIG. 11, the angled back wall of the groove 276 has substantially thesame shape as the angled back wall 240 of the first aspect illustratedin FIGS. 9 and 10. What differentiates this aspect of the embodimentfrom the previous aspect is that the rotational member 278 has a curvedresilient arm portion 280, in contrast to the substantially straightresilient arm member 224 of the previous aspect of the embodimentillustrated in FIG. 9. More precisely, the curved arm portion 280provides for greater flexibility and resiliency compared to the straightarm 224 illustrated in FIG. 9. In particular, as the tongue portion 270is pressed into the second arm 282 of the rotational member 278, thecurved resilient arm portion 280 is pressed against the angled back wallof the groove 276, causing the curved resilient arm portion 280 to beflexed, or bent, into a substantially straight position. The forceexerted by the tongue 270 against the rotational member 278 is spreadmore evenly across the length of the curve 280, instead of beingconcentrated at the core aperture 284 in the center of the rotatablelocking member 278. This minimizes the risk of cracking or breaking atthe point where the curved resilient arm portion meets the rotationalmember 278.

FIG. 12 illustrates the closed position or the installed condition oftwo panels in this aspect of the embodiment. Here the curved resilientarm 280 has been bent straight and is under tension as the panels arejoined. The convex shaped head 286 is in the closed position engagedinto the hooked shaped groove 288 on the tongue. Note that convex shapehead 286 and the hooked shaped groove 288 are substantially similar tothe corresponding shapes in the previous aspect of the embodimentillustrated in FIGS. 9 and 10. The difference here is that by providinga curved shaped resilient arm 280 on the rotational member 278, theforces present and working against the resilient arm 280 are distributedmore evenly across its length rather than being concentrated at theconnection point of the resilient arm where it meets the rotatablelocking member 278.

The three embodiments discussed above all share a characteristic whichis that the resilient arms are connected to a point substantially nearthe center of the rotatable locking member and that all of theseresilient arms are substantially thinner than either arm of therotatable locking member. Depending upon the type of material used tobuild the rotatable locking member, the forces acting upon the resilientarm may exceed the tolerances of the material, causing the arm to crackat the point of connection when the arm is subject to those forces. Inother words, when the rotatable locking member is forced against thetongue of the second panel and the rotatable locking member turnsforward pushing the resilient arm against the angled back wall of thegroove, the resilient arm of the rotatable locking member may crack.Depending on the type of material used in the rotational member 278, itis even possible in this context for the curved resilient arm portion280 of FIGS. 11 and 12 to crack.

A number of possible ways to overcome this problem are presented herein.For example, FIG. 21 illustrates a rotatable locking member 300 having aconvex shaped head 302 at the end of a first arm 303, which is oppositea second arm 304 at the other end of the rotatable locking member 300.The rotatable locking member 300 does not have a core aperture as seenin previous embodiments of the invention. However, rotatable lockingmember 300 has a resilient arm 306 that is connected substantially nearthe top and back of the first arm 303. This point of connection 307 issubstantially away from both the center of the rotatable locking memberas well as the point on the resilient arm 306 where the rotatablelocking member will be forced against the angled back wall of thegroove. In this third aspect of the embodiment the groove into which theplastic rotatable locking member 300 is placed is substantially similarto the angled grooves seen in previous aspects of this embodiment inFIGS. 1 through 12. In its operation, rotatable locking member 300 withresilient arm 306 is initially in an open position in which the secondarm 304 is projected out into the opening of a groove into which itsits, the tongue of the adjacent panel will press against the front face305 of the second arm rotating the rotatable locking member so that theconvex shaped head 302 swings forward to engage the corresponding hookedshaped groove in the tongue.

In this aspect of the embodiment the resilient arm 306 has asubstantially straight portion 308 extending from the point of contactto some point along a portion of the length of the resilient arm andthen a curved portion 309 from that point after the straight portion 308to the end of the resilient arm. The curved portion presses against therear surface of the angled groove and as the rotatable locking member isrotated towards the closed position, this curved portion 309 of theresilient arm 306 will be subject to forces and compress. However, giventhe shape of the resilient arm, the forces will be distributed along thelength of the curved portion 309 at the point where the curved portionmeets the straight portion 308, this point is referred to as P1, and ata second point, P2, where the straight portion of the resilient arm 308meets the first arm 303. It is contemplated that P1 and connection point307 may be the same point.

Because the forces from the installation of the flooring panels aredistributed along the length of the curved portion 309 at P1 and P2, nosingle point is subject to all the force of the resilient arm beingpressed against the angled back wall of the groove, thus makingrotatable locking member 300 less likely to crack at the point where theresilient arm 306 meets the first arm 303.

A fourth embodiment of the invention is presented with reference toFIGS. 13 through 18. In the previously discussed embodiments, it may bepossible, given the material out of which the rotational members aremade and the material out of which the flooring panel is made, for therotational member to slide or fall out of the groove in the first panel.In particular, during manufacturing or shipping of the flooring producthaving such rotational members, the rotational members may becomedislodge or may fall out of the grooves in the panels entirely. It thenbecomes difficult for the installer to locate the rotational member inthe product and re-insert it into the groove easily and without damagingit. This fourth embodiment addresses this problem, among others.

In a first aspect of this embodiment, a plastic insert member 400 isprovided with a first slot portion 402 and a rotatable locking memberportion 404. The slot portion 402 and the rotatable locking memberportion 404 are connected by an S-shaped resilient coil 406. The entireplastic insert member 400 is a single unitary and integrated body. Inthe first aspect of this invention illustrated in FIG. 13, rather than arib, an axial extension portion 408 is complemented by an axial grooveor notch 409 at the rear surface of the rotatable locking member 404. Ina second aspect of the invention, illustrated in FIG. 14, the slotmember 402 and the rotatable locking member portion 404 are additionallyconnected to one another by a rib 407 located at the tip of an axialextension or portion 408 which meets the center portion of the rearsurface of the rotatable locking portion 404.

Additionally, both aspects illustrated in FIGS. 13 and 14, include anumber of teeth or flanges 410 at an end portion of the slot member 402opposite the axial extension 408 which allow the slot insertion portion402 to slide into a corresponding groove formed into the first panel butprevent the slot insertion portion 402 from sliding out, thus holdingthe slot member 402 firmly in place while allowing the rotatable lockingmember portion 404 to rotate freely.

FIG. 15 illustrates the insertion member 400 of FIG. 13 inserted withina primary groove 412 having a rear slot 411, a top arcuate surface 413and a lower arcuate surface 414. The insertion member 400 is insertedinto the groove 412 such that the slot member 402 is secured within thegroove 413 via the flanges or teeth 410. This is accomplished by makingthe thickness of the slot insertion member 402 as measured from the tipof the teeth on opposite sides to be slightly greater than the width ofthe groove 413. For example, the thickness of the slot insertion portion402 may be 0.1 mm thicker than the width of the opening of groove 413.

In the open position illustrated in FIG. 15, in which the resilient coil406 is at its rest, or contracted position, the rotatable locking memberportion 404 having a first arm 415 and a second arm 416 hangs freely viathe S-shaped coil 406 which is in turn connected to the slot insertionportion 402 secured in the rear groove 413. The shape of the coil whenit is formed determines its rest position. If the coil is formed in awound-shape as in FIGS. 13-15, then stretching the coil straight or inan unwound position will create tension in the coil, which tries to pullthe coil back to its original shape. By contrast, if the coil is formedin a substantially straight or unwound shape (see FIG. 22 below), thenwinding it or coiling the coil with create tension that urges it to bereleased to its original straightened position.

When a second panel 418 is engaged with the first panel 417, the tongueportion 419 of the second panel 418 presses against the second arm 416of the rotatable locking member portion 404 of the insertion member 400.As the tongue presses against the second arm 416, the rotatable lockingmember portion 404 is pushed back against the slot member so that theaxial extension 408 enters and pressed against the axial groove 409.Thus, the tip of the axial extension 408 pressed into the axial groove409 becomes the point around which the rotatable locking member portion404 rotates. As the tongue 419 is pushed further into the groove 412,the rotatable locking member portion 404 rotates under tension so thatthe convex shaped head 420 enters and locks into the hooked shapedgroove 421. The hooked shaped groove 421 is designed such that theleading edge 422 over the hook shaped groove 421 is slightly higher thanthe bottom surface 423 of the hook shaped groove 421. This allows theconvex shaped head 420 to enter the hook shaped groove 421, touch thebottom surface 423 and be held in place in a horizontal direction by theslightly higher leading edge 422.

The rotation of the rotatable locking member portion 404 occurs undertension provided by the resilient coil 406. Specifically, while therotatable locking member rotates around the tip of the axial extension408 pressed into the axial groove 409, the resilient coil 406 becomesuncoiled or straightened as the convex shaped head 420 rotates forward.The extension of resilient coil 406 occurs under tension, urges therotatable locking member portion 404 to rotate back to its original openposition. However, the rotatable locking member is forced to rotatetowards the closed position by the force exerted by the tongue 419against the second arm 416.

The closed position of the joint according to this aspect of thisembodiment of the invention is illustrated in FIG. 16. Here, theresilient coil 406 is shown in its extended or unwound position exertingforce opposing the rotation of the rotatable locking member portion 404towards the closed position. Furthermore, at the end of the second arm416 the rotatable locking member portion 404 has a rear protrusion 424whose outer surface 425 has an arcuate or curved shape. The purpose ofthis rear extension 424 with the arcuate outer surface 425 is tofacilitate sliding of the rotatable locking member portion 404 againstthe surface 414 of the groove 412 as the rotatable locking memberportion 404 rotates from the open position to the closed position. Thisis helpful in circumstances where the material of the rotatable lockingmember portion 404 and the material of the first panel 417 wouldotherwise exert significant friction against one another. Moreparticularly, the arcuate shaped outer surface 425 provides for asmoother rotation of the rotatable locking member than would be presentif the rear extension 424 were not present.

In addition, FIGS. 15 and 16 illustrate a further aspect of theembodiment in which the rear groove 413 is not parallel to the uppersurfaces of the panels 417 and 418 but is rather at an angle. A varietyof placements of this rear groove 413 are contemplated by the presentinvention. Particularly, the groove depth, angle and vertical positionwithin the first panel 417 are selected to provide enough room above theslot member 402 and behind the rotatable locking member portion 404 intowhich the resilient coil member 406 can wind and unwind in the open andclosed positions, respectively. By allowing for greater space in thisregion where the resilient coil 406 will be present allows the coil tobe made longer or with a variety of shapes, such as an S-shape, a zigzagor accordion shape, a bowed shape or the like. By allowing for a longerresilient coil 406, all the forces acting upon the rotatable lockingmember 404 are distributed along the length of the curve and notconcentrated around a single point.

The S-shape or a continuous curve is better than a zigzag shape,provided there is enough room for it in the groove, because the zigzagshape will suffer extremes of tension at the vertexes of the angles,where the portions of the accordion fold, whereas an S-shaped or othershaped continuous curve will have the forces distributed continuouslyalong its length. This resists breakage and cracking better than azigzag or accordion shape. However, it is understood that the inventionis not limited to any particular shape of coil connecting the rotatablelocking member to the slotted insertion member. FIGS. 17 and 18illustrate further aspects of the present embodiment in which theinsertion member of a second aspect illustrated in FIG. 14 is insertedinto a rear groove 425 that is substantially parallel to the uppersurface of the flooring and placed in substantially the center of thepanel. In this embodiment, the operation of the joint is substantiallysimilar with a few notable exceptions.

In FIG. 17, the upper groove 427 of the second panel 418 does not have ahook shape but is rather a convex shape that is substantially smooth orflat along the lower surface 429. This corresponds to the shape of theconvex shaped head 428 of the rotatable locking member portion 404 whichis a substantially triangular shaped head with a rounded tip. In thisembodiment, there is no hooking mechanism when the head 428 is insertedinto the upper groove 427 by which the tongue 430 is held against thelocking member 404. In this aspect, the resilient coil 406 issubstantially similar to that of the previous aspect illustrated inFIGS. 13, 15 and 16. Returning to FIG. 17, because the axial extension435 in this aspect is connected to the rotatable locking member portion404 by a rib 407, it is not necessary for the second arm 426 to extendthe entire radius of the lower half of groove from the axial extension408 to the bottom surface 431 of the groove opening. Rather, it issufficient that the second arm only be long enough to be engaged by thetongue 430 as it enters the groove.

FIG. 18 illustrates this aspect of this embodiment of the invention inwhich the insertion member is in a closed position. Here, the rotatablelocking member portion 404 is in the closed position with the convexshaped head 428 secured in the groove 427 and in which the tongueportion 430 is pressed against a rear arcuate surface 431 of the lowerlip portion 432 of the groove. When locked in this position the tongue430 and the second panel 418 are secured both vertically andhorizontally within the groove. They are secured vertically by thepresence of the convex shaped head 428 of the rotatable locking memberwhich in turn presses against the upper arcuate surface 433 of thegroove. Thus, the top of the rotatable locking member 404 is pressedagainst the upper arcuate surface 433 of the groove. The upper surfaceof the tongue 430 is pressed against the lower surface of the convexshaped head 428 and the lower arcuate surface 431 of the groove ispressed against a lower rear surface 434 of the tongue. This holds thetongue securely in place against the rotatable locking member portion404.

Within this embodiment a number of points are important to themechanical operation of the joint. First, the placement of the slotportion of the slot groove 413 in the rear wall of the groove 412 is notcritical provided that it provides enough room above the slot portion402 for the resilient coil 406 to wind and unwind within that space. Thegreater the space provided, the greater the length that coil may bewhich allows greater forces to be distributed along its length. Thisgreater force will contribute to a more exaggerated or a more pronouncedsnap action when the rotatable locking member engages the groove abovethe tongue and enters the closed position.

In FIG. 16, certain points of contact and certain gaps provided withinthe joint enhance its operation. There is a first point of contact 440where the rear wall 441 of the tongue 419 touches or abuts the arcuatecurve 414 of the groove 412. This point 440 will be referred to as thefirst point of contact. A second point of contact 443 is where the lowertip 442 of the tongue 419 presses against the second arm 416 of therotatable locking member 404. A third point of contact 444 is presentwhere the upper arcuate surface 413 touches the top of the first arm 415of the convex shaped head 420. The fourth point of contact 445 ispresent where the raised tip 422 of the hook shaped groove 421 touchesthe under surface of the convex shaped head 420.

These four points of contact, the first point of contact 440, the secondpoint of contact 443, the third point of contact 444, and the fourthpoint of contact 445, provide for a continuous transmission of forcethroughout the joint to maintain the first and second panels 417 and 418in a secured and locked position relative to one another. Specifically,the second panel 418 is held in place in the vertical direction becauseany movement vertically will cause the tongue 419 to press against point445 with greater force. That force will be transmitted through the bodyof the convex shaped head 420 to where the first arm 415 meets the firstpanel 417 at point 444. Because the points 440, 444 and 445 are incontact when the joint is in the closed position, there is no room forthe second panel 418 to move in the vertical direction. Likewise, in thehorizontal direction, the first point of contact 440 and the secondpoint of contact 443 immobilize the tongue in a horizontal directionmaking it impossible for the tongue of the second panel to move out fromthe joint in a horizontal direction.

In order to uninstall the joint, the second panel 418 is rotate at anangle causing the rotatable locking member portion 404 to rotate backtowards its original open position, thus allowing the tongue to escapefrom the now open groove. By precisely controlling the size and shape ofthe joint in this manner, the two adjacent panels 417 and 418 may belocked so that their upper surfaces are at substantially the same planeso that they are locked relative to one another and so that there is noplay in the joint, but also allowing the panels once joined to be easilyseparated.

Furthermore, by providing some tolerance within the joint it may bepossible to provide some measure of play if this is desired. This can beachieved by making the rear surface of the tongue slightly narrower sothat the tongue may move back against the lower arcuate group 414 of thegroove 412.

In addition to these points of contact, a gap 446 is provided betweenthe convex shaped head 420 and the upper wall of the hook shaped groove447. This gap is important because it facilitates smooth movement androtation of the convex shaped head snapping forward into the hook shapedgroove when the rotatable locking member passes from the open to theclosed position. This reduces the friction, allows the joint to operatemore smoothly and provides for a more audible and pronounced snappingaction when the joint closes.

A fifth embodiment of the present invention is illustrated in FIGS. 19and 20. In this embodiment, rather than an axial extension at the end ofa slot member secured into a groove at the rear of a main groove in thefirst panel 417, this embodiment illustrates an insertion member 500having a hooked shaped head 502, a second arm 504, a resilient arm 505and a core aperture 506. What differentiates this embodiment from theprevious embodiments is that the rotatable member 500 is secured inplace through a protrusion 507 formed into and as part of the back wallof the groove 508. Because it is made from the core material of thefirst panel 517, this protrusion 507 acts as the axis of rotation aroundwhich the rotatable locking member 500 will rotate.

The operation of the joint is substantially similar to the embodimentsheretofore discussed, with the insertion member moving from an open to aclosed position as the panels are joined. In this embodiment, theresilient arm 505 engages the rear surface of the groove 508 underneaththe protrusion 507. Furthermore, the closed position of this jointillustrated in FIG. 20 is substantially similar to the closed positionof the joint illustrated in FIG. 4 with the exception that the rotatablelocking member rotates not around the point of force of the resilientarm but rather rotates around the protrusion 507. Thus, a differencebetween this embodiment and the first embodiment illustrated in FIGS. 1through 4 is that the axis of the rotation of the joint is separate fromthe point around which the rotatable locking member is provided withforce which is the contact point 510 between the resilient arm 505 andthe second arm 504. Because all of the force of the rotation isconcentrated where the resilient arm 505 meets the second arm 504 at thepoint 510, the forces acting at the protrusion 507 are not substantialand yet the joint is still provided with the locking action similar tothat of the first embodiment. Thus this embodiment shares a commoncharacteristic with the embodiment illustrated in FIG. 21 which is theseparation of the axis of rotation of the rotatable locking member fromthe point of contact between the resilient arm and the main body of therotatable locking member which is also the point where all of therotational force will be concentrated.

A sixth embodiment is illustrated in FIGS. 22 through 26, in which ainsertion member having a rotatable portion provided a locking operationin which the rotatable member moves from a closed position, to a openposition during locking, back to the closed position after locking. In afirst aspect of this invention, illustrated in FIG. 22, insertion member600 is provided with a rotatable member 602 having a convex head 604.The insertion member 600 has a main body 605 with an arcuate groove 606formed on an upper surface 607. The insertion member 600 also has a slotinsertion portion 603 substantially similar to the slot portion 402illustrated in FIG. 13. The slot insertion portion 603 may have one ormore teeth or flanges 608 that facilitate securing the slot insertionportion 603 into a corresponding slot at the rear of a groove. Inaddition, rotatable member 602 has a single arm 609 with a rounded orblunt tip 610 shaped and sized to correspond to the arcuate groove 606formed in the main body 605. The rotatable member 602 is connected tothe slot member 603 via a resilient coil 611. In the present aspect ofthe present embodiment, the resilient coil is shown with an S-shape butit is well within the scope of the invention for the coil to have any ofa variety of shapes which are flexible and able to distribute forcealong their length.

In an alternate aspect of this embodiment, illustrated in FIG. 23,rather than an arcuate groove 606 at the upper surface 607 of the mainbody 605, the upper surface 607 is substantially flat with a rib 612connecting the tip 610 of the rotatable member 602 to the main body 605.This rib provides additional support and also provide tension orresistance in addition to the tension supported by the coil 611.

FIGS. 24 through 26 illustrate the operation of a joint according tothis embodiment of the present invention using the insertion member 600of the first aspect illustrated in FIG. 22. In this embodiment, theinsertion member 600 begins in the closed position in which therotatable member 602 is rotated forward. In this position, the resilientcoil 611 is at rest and the rotatable member 602 is swung forward topartially close the groove 620 formed in the first panel 617. Inaddition, the slot member 603 is secured within a slot 612 at the rearof the groove 620. Note that because the insertion member 600 has nosecond arm extending below the axis of rotation of the rotatable member602, the lower portion of the groove 620 is substantially empty;however, it is understood to be within the scope of the invention thatthe groove may be formed much smaller, providing only enough space as isnecessary to accommodate tongue 621, rather than making the groove tohave a shape substantially similar to that of FIG. 15. In addition, itis also understood to be within the scope of the invention to place theslot 612 into which the slot portion 603 will fit much lower or at agreater angle in the rear groove 620 to provide maximum space in whichthe coil portion 611 can move.

As the tongue 621 enters the groove in FIG. 25, the tip 622 of thetongue 621 presses against the tip of head 604 causing the rotatablemember 602 to rotate around the arcuate surface 606 into which the tip610 of the rotatable member sits. As the rotatable member 602 rotatesinto the open position, the coil 611 is compressed, wound or contractedto place it under greater tension. When the tongue enters the jointcompletely and the tip 622 passes below the tip of head 604, the tensionin the coil 611 is released and the rotatable member 602 swings back toits original closed position. In this embodiment, the tip 622 of groove621 is slighter higher than the lower surface of the hook shaped groove623. Because of this, the rotatable member 602 is able to secure thetongue and the second panel 618 in place in both a horizontal andvertical direction. By making the coil 611 as long as possible, therotatable head will swing farther forward to close the groove providingfor a deeper extension into the hook shaped groove 623 which providesgreater strength and a more secure joint.

In the present invention, and in all of the exemplary embodimentsdiscussed herein, the adjacent flooring panels are joined by loweringthe panel having the tongue substantially vertically into the groove,with the adjacent panels coplanar relative to one another. Thus thejoints of the present invention do not require rotational installationor horizontal snap-action installation. Because of this, the use ofthese joints is not limited to the exterior side edges of the flooringpanel.

It is understood that the rotatable locking members and insertionmembers can be made of any material including metal, glass, wood,plastic, composite or fiberglass, but that it is likely that they willbe made of a type of plastic because plastic provides the greatestflexibility and the greatest ease of manufacturing, depending on theparticular shape of rotatable locking member. In addition, while theflooring panels may be made of medium or high density fiberboard (MDF orHDF) the flooring panels or their core material into which the tongueand grooves are formed maybe any of a variety of materials as well,including wood, particle board, chip board, or plastic.

1. A flooring panel, comprising: an interlocking joint having a firstside defining a first mating portion along the first side and a secondside defining a second mating portion along the second side, said secondside disposed opposite said first side; the first mating portion havinga substantially arcuate groove formed therein and extending along atleast a portion of the first side; a rotatable cam disposed in thegroove extending in a longitudinal direction along at least a portion ofthe first side; the rotatable cam having a central portion, a first armextending radially outwardly from the central portion along a firstaxis, a second arm extending radially outwardly from the central portionalong a second axis, and a resilient third arm extending radiallyoutwardly from the central portion along a third axis and disposed adistance from the second arm defined by a predetermined angle; the firstarm having a lever portion and a curved portion, the curved portionextending substantially perpendicularly to the lever portion defining asubstantially hook-shaped end; a lower lip extending outwardly from thefirst mating portion beyond the groove; said second mating portionhaving a tongue extending perpendicularly from said second side andextending along at least a portion of the second side and defining asubstantially concave groove along an undersurface receiving said lowerlip; said tongue having a substantially vertical face at least as longas the distance from the hook-shaped end of the first arm to the end ofthe second arm; said second mating portion further defining a lockinggroove formed therein above the tongue to receive the hook-shaped end ofthe first arm of the rotatable cam; and the second arm and the resilientthird arm bendable towards each other to create a biasing force, whereinthe biasing force impels the second arm toward the tongue such that asthe tongue advances in a direction toward the first mating portion, thehook-shaped end of the first arm moves into a mating position with thelocking groove, thus providing a tight locking connection.